Authentication and information system for reusable surgical instruments

ABSTRACT

A surgical instrument includes a handle having a handle frame, a microcontroller having at least one program and memory, and a handle interface supported by the handle frame and in electrical communication with the microcontroller. The instrument further includes a loading unit having a body configured for operative coupling to the handle frame of the handle, and an end effector coupled to a distal end of the body and configured to perform a surgical task. A bracket is mounted to the loading unit and includes a microchip having at least one of authentication data and identification data relating to the loading unit.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 15/607,759, filed May 30, 2017, the entire disclosure of which is incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to a surgical instrument having a reusable handle and removable and replaceable components, such as disposable or replaceable loading units. The present disclosure further relates to a surgical stapling instrument including an authentication and information system to authenticate and/or validate details of the loading unit to be coupled to the handle assembly.

2. Description of Related Art

Powered surgical instruments for use in endoscopic procedures are known. Typically, powered instruments include a reusable powered handle assembly, and a replaceable loading unit which is couplable to the handle assembly. The loading unit may be a single use loading unit (SULU) or a multiple use loading unit (MULU). The loading unit includes a body and an end effector, and is attached to the handle assembly, and/or an adapter assembly associated with the handle assembly, prior to surgery. The end effector may include a staple cartridge which houses a plurality of staples and an anvil in opposition to the staple cartridge.

In an effort to reduce costs and shorten procedure times, the handle assemblies may be adapted for use with a variety of loading units for application to tissue having different properties, e.g., thickness and density. For example, the loading units may have staples of different sizes and/or the staples may be arranged in different configurations. To ensure the handle assembly is programmed to operate with the attached loading unit, some loading units include an integrated circuit or chip, which communicates with the handle assembly to identify the type of loading unit. This eliminates the use of incompatible or non-authentic loading units, and reduces operator error when switching between different loading units.

The aforedescribed powered surgical instruments may include surgical staplers which are commonly used for stapling tissue within a body cavity. In this operative environment, the loading unit is likely to come in contact with fluids, e.g., blood, bile, and/or irrigation solutions. If the interconnections between the chip and the handle assembly are compromised, the chip may malfunction or data communications between the loading unit and the handle assembly could be disrupted, rendering the surgical stapler unstable or inoperable.

SUMMARY

Accordingly, the present disclosure is directed to further improvements in powered surgical instruments to increase the reliability of communications between the disposable loading unit and the handle assembly. In an exemplary embodiment, a surgical instrument includes a handle frame, a microcontroller having at least one program and memory and a handle interface supported by the handle frame and in electrical communication with the microcontroller. The instrument further includes a loading unit having a body configured for operative coupling to the handle frame of the handle, and an end effector coupled to the body and configured to perform a surgical task. A bracket is mounted to the loading unit and includes a microchip having at least one of authentication data and identification data relating to the loading unit. The bracket may be a shipping bracket adapted to prevent inadvertent movement of the components of the loading unit during shipping and/or handling. The bracket includes a bracket interface in communication with the microchip and configured for electrical coupling with the handle interface of the handle. In embodiments, the microchip includes data selected from the group consisting of cartridge size, staple arrangement, staple length, clamp-up distance, date of manufacture, expiration date, compatibility characteristics, unique identifier, and a number of other uses.

In certain embodiments, the bracket is mounted to a linear surgical stapling loading unit. Alternatively, the bracket may be mounted to circular stapling loading unit.

In embodiments, the bracket is releasably mounted to the loading unit.

In some embodiments, the handle includes first and second handle interfaces in communication with the microcontroller. The first handle interface is configured for electrical coupling with a bracket interface of a first bracket of a first loading unit and the second handle interface is configured for electrical coupling to a bracket interface of a second bracket of a second loading unit. In certain embodiments, each of the first and second brackets includes a microchip.

In embodiments, the first loading unit is a single use loading unit (SULU) and the second loading unit is a multiuse loading unit (MULU).

Other features of the present disclosure will be appreciated from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the authentication and information system for use with a powered surgical stapling system are described hereinbelow with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views:

FIG. 1 is a perspective view of a powered surgical stapling instrument illustrating the handle assembly, a loading unit and a shipping bracket incorporating the authentication and information system of the present disclosure;

FIG. 2 is an enlarged view of the area of isolation identified in FIG. 1 illustrating the handle interface of the handle assembly;

FIG. 3 is an enlarged view of the area of isolation identified in FIG. 1 illustrating the bracket interface of the shipping bracket and the microchip for coupling with the handle interface of the handle assembly;

FIG. 4 is a perspective view illustrating the shipping bracket removed from the loading unit;

FIG. 5 is a perspective view of the stapling instrument with the shipping bracket coupled to the handle assembly;

FIG. 6 is an enlarged view of the area of isolation identified in FIG. 5 illustrating the bracket interface of the shipping bracket coupled to the handle interface of the handle assembly;

FIG. 7 is a perspective view illustrating an embodiment of the stapling instrument including a handle assembly with first and second handle interfaces for coupling with shipping brackets of first and second different loading units; and

FIG. 8 is an enlarged view of the area of isolation identified in FIG. 7 illustrating the first and second handle interfaces of the handle assembly.

DETAILED DESCRIPTION

Embodiments of the presently disclosed surgical stapling system are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein the term “distal” refers to that portion of the surgical stapling instrument, or component thereof, farther from the clinician, while the term “proximal” refers to that portion of the surgical stapling instrument, or component thereof, closer to the clinician.

The present disclosure is directed to an authentication and/or information system for use with a universal powered handle assembly. The handle assembly is capable of individually coupling to multiple loading units adapted to perform various surgical tasks. The authentication and/or information system includes a microchip which is mounted to a shipping bracket of the loading unit and contains data associated with the loading unit. The shipping bracket includes a bracket interface which is mountable relative to a handle interface of the handle assembly. The microchip communicates with a microcontroller within the handle assembly to transmit specifications of the loading unit to the microcontroller. The microcontroller controls operation of the handle assembly, and, in turn, functioning of the loading unit based on the specifications transmitted by the microchip within the safety bracket. The location of the microchip within the shipping bracket eliminates the potential of irrigant, blood or other body fluids contacting and potentially affecting the integrity of the microchip thereby preserving functioning of the loading unit.

With reference initially to FIG. 1, a surgical stapling instrument including an authentication and information system according to the present disclosure is illustrated. The stapling instrument 10 includes a powered handle assembly 12, an adapter assembly 14 extending distally from the handle assembly 12, and at least one loading unit 16. The loading unit 16 is selectively connectable to the adapter assembly 14. The loading unit 16 may be a single use loading unit (SULU) or a multiuse loading unit (MULU). The loading unit 16 may be adapted to apply linear arrays of staples to tissue for linear stapling of tissue. Other types of loading units are envisioned including, e.g., a loading unit adapted to apply a circular array of staples in connection with a circular anastomosis, or any other type of loading unit having an end effector capable of performing a surgical task on tissue. A detailed description of the handle assembly 12, the adapter assembly 14, and the loading unit 16 may be ascertained by reference to commonly-assigned U.S. Pat. No. 8,968,276 to Zemlock et al., the entire contents of which are incorporated by reference herein.

With reference to FIGS. 1-2, the handle assembly 12 includes a handle frame 18 which contains a microcontroller 20 (shown schematically) having memory, circuitry, logic etc. for controlling operation of the instrument 10. The handle assembly 12 further includes a motor and associated gearing (not shown) which are powered through a power source. The power source may be any suitable power source including but not limited to a battery (rechargeable and/or non-rechargeable) or an AC wall outlet. The handle frame 18 includes at least one handle interface 22 in electrical communication with the microcontroller 20. The handle interface 22 may include a female receptacle or socket extending within the handle frame 18. Alternatively, the handle interface 22 may include a magnetic coupling or wireless means.

The adapter assembly 16 includes mechanical components adapted to convert movement, e.g., rotation or linear movement, of the motor and associated gearing to control operation of the loading unit 16. The loading unit 16 includes an elongate body 22 and an end effector 24 coupled to the body 22. The body 22 is mountable to the adapter assembly 14 and, in embodiments, is releasably mountable to the adapter assembly 14. The body 22 of the loading unit 16 includes various pushers, links, gears etc. which couple with corresponding components within the adapter assembly 14 to control operation of the end effector 24. As discussed hereinabove, the end effector 24 is adapted to perform a surgical task and, in embodiments, include a staple cartridge 26 and an anvil 28 for applying a linear array of staples to tissue.

As best depicted in FIGS. 1, 3 and 4 the stapling instrument 10 further includes a shipping wedge or bracket 30 which is mountable to the loading unit 16. In FIG. 4, the bracket 30 is shown removed from the loading unit 16. The bracket 30 may be configured to engage and prevent movement of the drive components of the loading unit 16 to prevent inadvertent firing or movement of the components of the loading unit 16 during shipping and handling, and prior to mounting of the loading unit 16 to the adapter assembly 14. The bracket 30 may extend between the staple cartridge 26 and the anvil 28, and also may protect the components from damage prior to use. The bracket 30 may be a component which snaps on to the loading unit 16 or be any other component configured to at least partially enclose, or be mounted to, the loading unit 16 for any purpose.

With reference to FIGS. 3 and 4, the bracket 30 includes a microchip 32 (shown in phantom) mounted to, or at least partially embedded within, the body of the bracket 30. The microchip 32 includes any chip capable of storing the specifications of the loading unit 16, such as, without limitation, cartridge size, staple arrangement, staple length, clamp-up distance, date of manufacture, expiration date, compatibility characteristics, a unique identifier (e.g., a serial number), and/or number of uses, and transmitting the specifications to the handle assembly 12. In some embodiments, the microchip 32 includes an erasable programmable read only memory (“EPROM”) microchip. The handle assembly 12 may adjust the firing forces, firing stroke, and/or other operational characteristics in accordance with the specifications transmitted from the microchip 32 within the bracket 30. It is further envisioned that the microchip 32 may include write capabilities which permits communication between the handle assembly 12 and the microchip 32 that the bracket 30 and thus the loading unit 16 has been used, which can prevent reloading or reuse of an expended reload assembly, or any other unauthorized use.

In some embodiments, the microchip 32 includes a secure authentication microchip, such as, without limitation, a DS28E15 DeepCover™ Secure Authenticator with 1-Wire SHA-256 and 512-Bit User EEPROM, manufactured by Maxim Integrated® of San Jose, Calif. In these embodiments, the contents of the microchip 32, and the communications between the microchip 32 and the handle assembly 12, are encrypted to prevent unauthorized access. This eliminates the use of low-quality counterfeit, re-manufactured, or “knock-off” loading units, which, in turn, reduces risk to patients by ensuring that only fresh, authentic loading units are used during surgical procedures. In addition, the likelihood that medical facilities and/or surgeons may be exposed to liability for unwittingly using counterfeit loading units is greatly curtailed, thus reducing the overall costs to society for delivering medical services. In some embodiments, the microchip 32 utilizes a “1-wire” communications interface whereby a single signal conductor is employed, together with a ground conductor, for bidirectional serial communications between the microchip 32 and the handle assembly 12.

The microchip 32 within the bracket 30 is in electrical communication with a bracket interface 34 of the bracket 30. The bracket interface 34 is couplable to the handle interface 22 of the handle assembly 12. The bracket interface 34 may include a plug connection which is positionable within the receptacle of the handle interface 22 of the handle frame 18. Alternatively, the bracket interface 34 may include a bus, pin connection, magnetic break away connection, wireless means, etc. The bracket interface 34 when mounted relative to the handle interface 22 establishes electrical communication between the microchip 32 of the bracket 30 and the microcontroller 20 of the handle assembly 12.

The use of the authentication system will now be discussed. Referring now to FIG. 4, when it is time to connect the loading unit 16 to the adapter assembly 14, the clinician removes the bracket 30 from the loading unit 16 thereby exposing the end effector 24. In the embodiment depicted in FIG. 4, the loading unit 16 is a linear stapling loading unit (e.g., either a SULU or a MULU) having the staple cartridge assembly 26 and the anvil assembly 28. The staple cartridge assembly 26 and the anvil assembly 28 are adapted for relative movement between an open condition depicted in FIG. 4 and an approximated condition in which tissue is clamped between the assemblies 26, 28.

With reference to FIGS. 5-6, the bracket interface 34 is then mounted to the handle interface 22 to thereby electrically couple the microchip 32 of the bracket 30 associated with the loading unit 16 with the microcontroller 20 within the handle assembly 12. Authentication of the type and/or details of the loading unit 16 are ascertained via communication of the data within the microchip 32 with the microcontroller 20. Upon authentication of the type of loading unit and verification that it is a compatible loading unit, the bracket 30 may be removed from the handle interface 22 of the handle frame 18, and the staple cartridge assembly 26 and the anvil assembly 28 may be positioned about tissue, and the instrument 10 fired. In embodiments, the microchip 32 may include write capabilities which allows the loading unit 16 to be fired one time subsequent to removal of the bracket 30 from the handle frame 20. This may prevent reloading or reuse of the expended loading unit 16.

FIGS. 7-8 illustrate one embodiment where the handle assembly 12 includes first and second handle interfaces 36, 38 each being in electrical communication with the microcontroller 20. In embodiments, the first handle interface 36 may be dedicated to a loading unit 40 of the SULU type and the second handle interface 38 may be dedicated to a loading unit 42 of the MULU type. Thus, depending on the type of loading unit, e.g., either SULU or MULU, the respective bracket interface of the shipping bracket 30 associated with the loading unit 40, 42 is coupled to the appropriate first or second handle interface 36, 38 of the handle assembly 12. Information may be transmitted between the microchip 32 within the shipping bracket 30 and the microcontroller 20 in the aforedescribed manner. It is contemplated that different loading units may have structurally different shipping brackets thus requiring the need for a second handle interface. Other types of handle interfaces adapted for use with different loading units are also envisioned.

The authentication system may be incorporated in various types of loading units having different end effectors including the loading unit for a circular anastomosis apparatus as disclosed in commonly assigned U.S. Patent Publication No. 20160361057 to Williams, the entire contents of which are incorporated by reference herein.

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present loading units and surgical stapling instruments without departing from the scope of the present disclosure. While several embodiments of the loading units and surgical stapling instruments disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

1-8. (canceled)
 9. A surgical instrument, comprising: a handle including a microcontroller having at least one program and memory; a handle interface in electrical communication with the microcontroller; and at least one loading unit including: an elongate body; an end effector adapted to be coupled to the elongate body; and a shipping wedge mounted to the end effector, the shipping wedge adapted to prevent inadvertent firing of the end effector and including a microchip, the microchip storing at least one of authentication data and identification data relating to the loading unit.
 10. The surgical instrument of claim 9, wherein the microchip is at least partially embedded within the shipping wedge.
 11. The surgical instrument of claim 9, wherein the microchip of the shipping wedge includes data selected from the group consisting of cartridge size, staple arrangement, staple length, clamp-up distance, date of manufacture, expiration date, compatibility characteristics, unique identifier, and number of uses.
 12. The surgical instrument of claim 9, wherein the end effector includes a linear surgical stapling instrument.
 13. The surgical instrument of claim 9, wherein the end effector includes a circular stapling loading unit.
 14. The surgical instrument of claim 9, wherein the shipping wedge is releasably mounted to the loading unit.
 15. The surgical instrument of claim 9, wherein the at least one loading unit includes a first loading unit and a second loading unit, and the shipping wedge includes a first shipping wedge mounted to the first loading unit and a second shipping wedge mounted to the second loading unit.
 16. The surgical instrument of claim 15, wherein the handle interface includes first and second handle interfaces in communication with the microcontroller and the first and second shipping wedges include first and second shipping wedge interfaces, respectively, the first handle interface configured for electrical coupling with the first shipping wedge interface and the second handle interface configured for electrical coupling to the second shipping wedge interface.
 17. The surgical instrument of claim 16, wherein each of the first and second shipping wedges includes a microchip.
 18. The surgical instrument of claim 17, wherein the first loading unit is a single use loading unit (SULU) and the second loading unit is a multiuse loading unit (MULU).
 19. The surgical instrument of claim 9, wherein the end effector includes a staple cartridge and an anvil for applying staples to tissue.
 20. The surgical instrument of claim 18, wherein handle includes indicia to identify the first and second handle interfaces.
 21. A loading unit comprising: an elongate body; an end effector coupled to the elongate body, the end effector including a staple cartridge and an anvil for applying staples to tissue; and a shipping wedge mounted to the end effector, the shipping wedge adapted to prevent inadvertent firing of the end effector and including a microchip, the microchip storing at least one of authentication data and identification data relating to the loading unit.
 22. The loading unit of claim 21, wherein the microchip is at least partially embedded within the shipping wedge.
 23. The loading unit of claim 21, wherein the shipping wedge includes a shipping wedge interface in communication with the microchip, the shipping wedge interface configured for electrical coupling with a surgical instrument.
 24. The loading unit of claim 21, wherein the microchip of the shipping wedge includes data selected from the group consisting of cartridge size, staple arrangement, staple length, clamp-up distance, date of manufacture, expiration date, compatibility characteristics, unique identifier, and number of uses. 